7.

Computerized Layout Technique

7.1: Automated Layout DEsign Program ( ALDEP )

1. Construction algorithm
2. Input requirements are as follows:
a. Relationship chart
b. Department areas
c. Sweep width
3. Arbitrarily selects first department
4. Allows fixed departments

7.1.1. Solution Steps in ALDEP

1. First department selected randomly.

2. Next department selected based on relationship with placed departments:
a. If more than one with same relationship, choice random.
b. If no departments with minimally acceptable relationship exist, choice is random.
3. Place first department in the upper left corner and extend downward.
4. Additional departments begin where the previous one ended.
5. Sweep width < area of smallest department: Why ?

Sweep width = 3 squars

Sweep width = 2 squars

ALDEP Pacement Procedures

88
Example 1:
An activity relationship chart is shown below for the company. Construct the layout by
using ALDEP method. Values of A = 64, E = 16, I = 4, O = 1, and U = 0
Area
m2
1. Office 70
O
2. Foreman 20 E
I U
3. Conference R. 30 I U
U E U
4. Receiving 40 U I
U U
5. Parts shipment 30 A
A
6. General storge 50

Solution:
Start laying out departments Top Down and Left to Right, when you came to border
continue laying out Bottom Up and Left to Right.
Let 1 grid = 5 m2 and Sweep width = 3

Area # of
m2 grids
1. Office 70 12
O
2. Foreman 20 04 E
I U
3. Conference R. 30 06 I U
U E U
4. Receiving 40 08 U I
U U
5. Parts shipment 30 06 A
A
6. General storge 50 10

for office = 70 / 5 = 12
Sweep width = 3 less than foreman =4

Total of grids = 48 = 6 x 8 = 6 x9

89
Suppose department 1 is selected first to be placed

1 1 1
1 1 1
1 1 1
1 1 1
1 1

Department 3 is selected due to " E " rating with 1

1 1 1
1 1 1
1 1 1
1 1 1
1 1 3
3 3 3 3 3

Department 2 is selected due to " I " rating with 3

1 1 1
1 1 1
1 1 1
1 1 1
1 1 3 2 2 2
3 3 3 3 3 2

Department 5 is selected due to "E " rating with 2

1 1 1
1 1 1
1 1 1 5 5 5
1 1 1 5 5 5
1 1 3 2 2 2
3 3 3 3 3 2

90
 Department 6 is selected due to "A " rating with 5
1 1 1 6 6 6 6 6 6
1 1 1 6 6 6 6
1 1 1 5 5 5
1 1 1 5 5 5
1 1 3 2 2 2
3 3 3 3 3 2

Department 4 is selected due to "A " rating with 6

1 1 1 6 6 6 6 6 6
1 1 1 6 6 6 6 4 4
1 1 1 5 5 5 4 4 4
1 1 1 5 5 5 4 4 4
1 1 3 2 2 2
3 3 3 3 3 2

Total score of the final layout is computed as following

Adjacent Dept. Rating Value

13 E 16
23 I 04
25 E 16
56 A 64
4-6 A 64
Total Score 164

7.2. Computerized Relative Allocation of Facilities

Technique ( CRAFT )

CRAFT is an improvement type layout algorithm, it starts with the initial layout,
which typically represents the actual layout of an existing facility but may also represent
a prospective layout developed by another algorithm. CRAFT begins by determining the
91
centroids of the departments in the initial layout. It then calculates the rectilinear distance
between pairs of department centroids and stores the values in a distance matrix. The
initial layout cost is determined by multiplying each entry in the from to ( or
qualitative data ) with the corresponding entries in the unit cost matrix ( i.e, the Cij values
) and the distance matrix.
The main objective behind CRAFT is to minimize total transportation cost:

Where: Fij = material flow between departments i and j

Cij = unit cost to move materials between departments i and j
Dij = rectilinear distance between departments iI and j

7.2.1. Steps in CRAFT

1. Calculate centroid of each department and rectilinear distance between pairs of

departments centroids ( store in a distance matrix ).
2. Find the cost of the initial layout by multiplying the following:
a. From To chart.
b. Unit cost matrix, and
c. From - To ( distance ) matrix
3. Improve the layout by performing all possible two ways exchanges.
a. At each iteration, CRAFT selects the interchange that results in the maximum
reduction in transportation costs.
b. These interchanges are continued until no further reduction is possible.

7.2.2. CRAFT: Distance Between Two Departments

Example 2.

100
90 A D

80 ( 80 , 85 )

- Is this a good 70
( 30 , 75 )
layout ? 60 C
- If not, can it be
improved ? 50
40 B

30 ( 80 , 35 )

20
( 30 , 25 )
10

10 20 30 40 50 60 70 80 90 100

92
 TO
FROM A B C D

2 7 4
A

3 7 Matreial handling trips

B

6 7 3
C

7 7 3
D

Consider the problem of finding the distance between two adjacent departments,
separated by a line only.
People needs walking to move from one department to another, even when the
departments are adjacent.
An estimate of average walking required is obtained from the distance between
centroids of two departments.
Centroid of a rectangle is the point where two diagonals meet. So, if a rectangle
has two opposite corners ( x1 , y1 ) and ( x2, y2 ) then the centroid is :
x x 2 y1 y 2
( 1 , )
2 2
The distance between two departments is taken from the distance between their
centroids.
People walks along some rectilinear paths. An Euclidean distance between two
centroids is not a true representative of the walking required. The rectilinear
distance is a better approximation.
So, Distance (A,B) = rectilinear distance between centroids of departments A and
B

Let
Centroid of Department A = ( XA , YA )
Centroid of Department B = ( XB , YB )

Then, the distance between departments A and B, Dist(A,B) = X A X B X A YB

The distance formula is illustrated with an example 2 The distance between

departments A and C is the rectilinear distance between their centroids (30,75) and
(80,35). Distance (A,C) = X A X C Y A YC 30 80 75 35 90
The distance between each two departments as shown in the next table:

93
 To
F ro m A B C D
A 50 90 60
B 50 60 110
C 90 60 50
D 60 110 50

7.2.3. CRAFT: Total Distance Traveled

If the number of trips between two departments are very high, then such
departments should be placed near to each other in order to minimize the total
distance traveled.
Distance traveled from department A to B = Distance (A,B) Number of trips
from department A to B
Total distance traveled is obtained by computing distance traveled between every
pair of departments, and then summing up the results.
Given a layout, CRAFT first finds the total distance traveled.

TO To
FROM A B C D F ro m A B C D
A
2 7 4
A 50 90 60
B
3 7
x B 50 60 110 =

C
6 7 3 C 90 60 50
D
7 7 3 D 60 110 50

94
 To
F ro m A B C D
A 100 630 240
B 150 300 770
C 540 420 150
D 420 770 150
Total distance traveled = 100+630+240+.+ 770 + 150 = 4640

7.2.4. CRAFT: Savings

As stated before, given a layout CRAFT first finds the total distance traveled as
illustrated on the previous before ( section: 7.2.3 ) . CRAFT then attempts to
improve the layout by pair-wise interchanges.
If some interchange results some savings in the total distance traveled, the
interchange that saves the most (total distance traveled) is selected.
While searching for the most savings, exact savings are not computed. At the
search stage, savings are computed assuming when departments are interchanged,
centroids are interchanged too. This assumption does not give the exact savings,
but approximate savings only. Exact centroids are computed later.
Savings are computed for all feasible pairwise interchanges. Savings are not
computed for the infeasible interchanges.
An interchange between two departments is feasible only if the departments have
the same area or they share a common boundary. For the layout shown on above:
feasible pairs are {A,B}, {A,C}, {A,D}, {B,C}, {C,D}
and an infeasible pair is {B,D}
For the layout shown on example 2, savings are not computed for interchanging B
and D. Savings are computed for each of the 5 other pair-wise interchanges and
the best one chosen.
After the departments are interchanged, every exact centroid is found. This may
require more computation if one or more shape is composed of rectangular pieces.

7.2.4.1: CRAFT: A Sample Computation of Savings from a Feasible

Pairwise Interchange

To illustrate the computation of savings, we shall compute the savings from

interchanging Departments C and D. New centroids:
A (30,75) Unchanged
B (30,25) Unchanged
C (80,85) Previous centroid of Department D
D (80,35) Previous centroid of Department C

95
 Note: If C and D are interchanged, exact centroids are C(80,65) and D(80,15). So, the
centroids C( 80, 85 ) and D( 80, 35 ) are not exact, but approximate.

100
90 A C
80

70
( 30,75 )
60
( 80,65)
50
40 B
30

20 D
( 30,25)
10 ( 80,15)
0
10 20 30 40 50 60 70 80 90 100

The first job in the computation of savings is to reconstruct the distance matrix
that would result if the interchange was made.
The purpose of using approximate centroids will be clearer now.
If the exact centroids were used, we would have to recompute distances between
every pair of departments that would include one or both of C and D.
However, since we assume that centroids of C and D will be interchanged, the
new distance matrix can be obtained just by rearranging some rows and columns
of the original distance matrix. This will now be shown

The matrix on the left is the previous matrix, before interchange. The matrix on the
right is after.
Dist (A,B) and (C,D) does not change.
New dist (A,C) = Previous dist (A,D)
New dist (A,D) = Previous dist (A,C)
New dist (B,C) = Previous dist (B,D)
New dist (B,D) = Previous dist (A,C

96
 To To
From A B C D From A B C D

A 50 90 60 A 50 60 90

B 50 60 110 B 50 110 60
90 60
C 50 C 60 110 50

D 60 110 50 D 90 60 50

TO To
FROM A B C D From A B C D

2 7 4 A 50 60 90
A

3 7 110 60 =
B x B 50

6 7 3 C 60 110 50
C
7 7 3 D 90 60 50
D

To
F ro m A B C D
A 100 420 360
B 150 550 420
C 360 770 150
D 630 420 150
Total distance traveled = 100 + 420 + 360 + + 420 + 150 = 4480
Savings = 4640 4480 = 160

7.2.4.2: CRAFT: Improvement Procedure

To complete the exercise

1. Compute savings from all the feasible interchanges. If there is no (positive)
savings, stop.
2. If any interchange gives some (positive) savings, choose the interchange that
gives the maximum savings
97
 3. If an interchange is chosen, then for every department find an exact centroid after
the interchange is implemented
4. Repeat the above 3 steps as longs as Step 1 finds an interchange with some
(positive) savings.

7.2.5. CRAFT: Exact Coordinates of Centroids

Sometimes, an interchange may result in a peculiar shape of a department; a shape

that is composed of some rectangular pieces
For example, consider the layout on example 2, and interchange departments A
and D. The resulting picture is shown below

100
A
90 D

80
70

60 C
50
40 B

30

20
10

10 20 30 40 50 60 70 80 90 100

How to compute the exact coordinate of the centroid (of a shape like A)?

Let: 100
A1= Area A1 A
90 A1
Centroid of A1= ( X1, Y1)
80 ( 70,85)
A2= Area A2
Centroid of A2 = ( X2, Y2 ) 70
60 A2
( 30,65 )
50
10 20 30 40 50 60 70 80 90 100

A = A1 + A2 = ( 60 * 30 ) + ( 60 * 20 ) = 1800 + 1200 = 3000

A1 X 1 A2 X 2 1800(30) 1200(80)
X Coordinate of the centroid of A = = 54
A1 A2 3000

98
 A1Y1 A2Y2 1800(75) 1200(85)
Y Coordinate of the centroid of A = 79
A1 A2 3000
100
90 D A
( 15,85 )
( 54,79 )
70

C
50
B
30 ( 80,35)

( 30,25)
10

10 30 50 70 80 100

To To
From A B C D From A B C D

A 2 7 4 A 78 70 45

B 3 5 7 B 78 60 75
X =
C 6 7 3 C 70 60 115

D 7 7 3 D 45 75 115

To
From A B C D

A 156 490 180

B 234 300 525

C 420 420 345

D 315 523 345

Total distance traveled = 156 + 490 + 180 + + 523 + 345 = 4253
Saving = 4640 4253 = 387
An interchange between A and D is better than an interchange between C and D.
Saving between A and D 387 saving between C and D 160

Assignment # 7

99
Q.1:

An activity relationship chart is shown below for the company. Construct the layout by
using ALDEP method. Values of A = 1000, E = 100, I = 10, O = 5, and U = 0

A 2100
A
B 2100 E
E I
C 2100 A O
U O U
D 2800 U U E
E O U
E 1500 I U
E I
F 1500 O
A
G 2900
Q.2:

An activity relationship chart is shown below for the company. Construct the layout by
using ALDEP method. Values of A = 10000, E = 1000, I = 100, O = 10, and U = 0, and X
= - 5000

Receiving 2500
A
Punch Press 5500 I
A O
Press Bending 2500 O U
I E U
Press Forming 2500 X E U
U E I E
Riveting 1500 U A U
O U E
Power Sawing 2500 I O
U O
Power Draw 2000 I
U
welding Robot 1000

Q.3:

100
 Explain the steps CRAFT would take with the following problem and determine the
final layout.

From - To Chart Initial Layout

100

A B C D E 90 A B
( 90,90)
80

A 3 2 1 70 C
60 ( 30,70 )

B 1 3 50 ( 90,60)

40
4
C 1 30 D E
20

D 10 ( 30,25)
( 90,20)
0

E 10 20 30 40 50 60 70 80 90 100 110 120

Q.4:

A manufacturing concern have Six departments labeled A, B, C, D, E, and F located in a

rectangular building as shown below:

60

50 A
C
E
40

30
B
20 D

F
10

20 40 60
Initial Layout

Suppose the flow data, the unit cost, and the distance matrix are given as follows:

101
 A B C D E F A B C D E F A B C D E F

A 0 8 0 4 0 A 30 25 55 50 80 A 0 1 0 1 1

B 0 5 0 2 B 45 25 60 50 B 1 4 0 1

C 0 1 0 C 30 25 55 C 3 0 2

D 6 0 D 45 25 D 1 2

E 4 E 30 E 1

F F F

Flow - Between Matrix Distance Matrix Cost / unit diatance

a. Given the above data and initial layout, which department pairs will not be
considered for exchanged.
b. Compute the cost of the initial layout.
c. Compute the estimated layout cost assuming that the departments E and D are
exchanged.

102